SURGICAL FILE INSTRUMENT CONSTRUCTION WITH MECHANISM TO CONVERT ROTARY MOTION TO RECIPROCAL MOTION

Description

BACKGROUND OF THE INVENTION

FIELD OF THE INVENTION

[0001] This invention relates to a surgical file that is used in a surgical procedure for removing bone or portions thereof from a patient. More particularly, the invention relates to a surgical file for cutting, removing, grinding, shaping and sculpturing bone and to the surgical file construction and the mechanism for imparting reciprocal motion to the reciprocating file of the surgical instrument.

DESCRIPTION OF RELATED ART

[0002] U .S. Patent No. 7,390, 330 granted to Harp on June 24, 2008 describes a surgical file that has a sundry of applications that may be used by a surgeon for the treatment of certain types of pathology. Essentially, this patent relates to a surgical file that is similar to the surgical file described in the present patent application and the invention described in this patent application patentably distinguishes over the surgical file disclosed in the 7,390,330 patent ('330), supra while also, obtaining unexpected results for the reasons that will be described herein below. The '330 patent, supra, discloses a shielded reciprocating surgical file system and allows a user to navigate the file into hard to access parts of the patient's body. A transmission mechanism converts rotary motion from a motor into reciprocating motion and pump mechanism and an irrigation system that supplies fluid to the surgical site.

[0003] To obtain the reciprocal motion from the rotary motion, the structure disclosed in the '330 patent, supra, utilizes a torus transmission device which may include an integral shaft or a rigidly connected shaft. The torus drive and drive shaft are rotatable about a central rotation axis
and has a generally circular or curvilinear cam portion with the torus central axes being at an offset angle. The variable thickness of the torus cam surface produces a hybrid dual or twin torus. As will become evident from the description to follow, the inventive mechanism described in this application provides a far less complicated transmission system for converting the rotary motion to reciprocal motion as will be described in more detail herein below.

[0004] The file member of the surgical file instrument includes an elongated angular shaft portion having a blade on the distal end and a tang on the proximal end and is encapsulated in an elongated cylindrical tube of plastic material disposed in an elongated generally "infinity symbol" shaped aperture and having lumens formed therein. The lumens serve to define passageways extending externally of the patient to the surgical site. The distal end of the elongated tube flairs into a generally flat portion with judicious located curvatures that together define a guide for the blade of the file.

[0005] As was discussed in the '330 patent, supra, the present invention has utility for many medical procedures that are typically the concern in neurosurgery, orthopedic surgery and plastic surgery, amongst others. For example in neurosurgery, the neuroforamen may need enlargement and the file can be instrumental in removing rigid bony vertebral structure to allow the nerve roots to pass there through. In orthopedic surgery the knee may require sculpturing. And, in plastic surgery bone and tissue sculpturing may be required for nose reshaping and rhinoplasty. The surgical file is efficacious for use in these types of procedures and methodology.

[0006] US 2006/0206117 A1 discloses a reciprocating file system for precisely removing bone and/or other tissue. US 4940061 discloses a motor powered instrument for removing tissue samples from a tissue mass. WO 2008/058157 discloses systems for performing therapeutic or diagnostic procedures at a remote site.

SUMMARY OF THE INVENTION

[0007] The present invention provides a surgical file instrument as claimed in claim 1.

[0008] An object of this invention is to provide an improved surgical file. A feature of this invention is to provide for a surgical file an improved mechanism for converting rotary motion to reciprocal motion and is characterized as being compact and efficacious in operation, contributes to the minimal size of the instrument and enhances the feel while being used by a surgeon

[0009] Another feature of this invention is the utilization of a planetary gear system for implementing the conversion of rotary to reciprocal motion.

[0010] Another feature of this invention is the utilization of thrust pins operably connected to the cylindrical cam and grounded to the surgical instrument casing.

[0011] Another feature of this invention is the utilization of a cylindrical cam with a single follower and drum combination.

[0012] Another feature of this invention is the utilization of a solid rod made from a plastic material mounted in an outer tubular casing including an elongated central aperture for the file assembly and lumen for defining passageways exterior of the surgical file instrument extending to the surgical site.

[0013] Another feature of this invention is that the elongated central aperture for supporting the file of the file assembly is shaped in a configuration resembling the infinity symbol.

[0014] The foregoing and other features of the present invention will become more apparent from the following description and accompanying drawings

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] 

Fig. 1 is an exploded view in perspective illustrating the invention;

Fig. 2 is an assembled a sectional view of the surgical file instrument of this invention;

Fig. 2A is a sectional view taken along lines 2A-2A in Fig. 2;

Fig. 3 is a partial enlarged view in perspective and section illustrating the motion converter of this invention:

Fig. 4 is an enlarged view in perspective of the drum depicted in Fig. 3;

Fig. 5 is an exploded view in elevation illustrating the file assembly of this invention;

Fig. 6 is an enlarged partial view in perspective of the file, the file blade, the file shield and the file assembly;

Fig. 7 is a sectional view taken along lines 7-7 of Fig. 6; and

Fig. 8 is a sectional view taken along lines 8-8 of Fig 6.

DETAILED DESCRIPTION OF THE INVENTION

[0016] As will be appreciated by those skilled in this technology, the configuration of the file assembly and particularly to the blade and tang may take many different forms and designs without departing from the scope of the invention. For example, the dimensions of the angles of the file assembly may be different or non-angularly shaped, the types of blade of the file may be different from the one depicted in the preferred embodiment.

[0017] The invention can best be seen by referring to Figs. 1 - 4 which show the surgical file instrument generally illustrated by reference numeral 10 comprising the outer split casing 12, the battery 14, electric motor 16, the motion converter 18, and the file assembly 20. In the assembled condition as seen in Fig. 2, the casing 12 is formed in two generally cylindrical members 22 and 24 that are suitably attached by the screws 26 threadably engaging the threaded lugs 28. The terminals 30 and 32 connect the motor 16 to the battery 14 for powering the motor and driving drive shaft 34. In turn, the drive shaft 34 provides rotary motion to the motion converter 18, as will be described in detail herein below. As noted in Fig. 2, the drive shaft 34 is coupled to the driven shaft 38 of the planetary system 40 of the motion converter 18 for rotating the same. As will be explained below, the planetary gear system 40 rotates the cam 69 via the follower 44 (see Fig. 3), which, in turn, translates the drum 49 and shaft 48 to impart reciprocal motion.

[0018] The file assembly 20 (see Fig. 5) includes the file 50 having an angular shaft 52, a blade 54 and tang 56. Tang 56 includes hole 58 (see Fig. 5) that cooperates with a complementary threaded hole 60 formed in the end portion 62. A suitable bolt 61 fitted into hole 58 is threaded to hole 60 and connects the file 50 to drum 49 for imparting reciprocation to the file 50.

[0019] It is typical in this type of instrument to provide irrigation to the surgical site. To this end, the casing 12 includes port 42 and the lubricant transmittal tube 44 that is connected to the lumen 46 formed in the file assembly 20.

[0020] The next portion of this application will describe the inventive cam/drum configuration of the motion converter 18. The pinion gear 66 is directly coupled to the drive shaft 34 of motor 16. Pinion gear 66, in turn, meshes with each of the planetary gears 70, (three in number) which, in turn, meshes with the fixed ring gear 72. Ring gear 72 in its preferred embodiment is formed integrally by molding it to the outer casing 73. Alternatively ring gear 72 may be fixed to the outer casing 73 via the dowel pin 75 disposed in the slot 77 formed in the flange 79. As is apparent from
Fig. 3, each of the planetary gears 70 are rotary supported to stub shaft 74 which is suitably pinned to platen 76. Platen 76 is a portion of the rotating cam 69 which is rotated by the spinning planetary gears 70. Cam 69 includes the main body 71 that has formed therein the cam slot 80 that is designed to produce reciprocal motion as will be apparent from the following description. Follower 44 fitted into the cam slot 80 is pinned via pin 86 to drum 88. As noted, and in accordance with this invention, a single cam follower is all that is necessary to drive drum 88. Drum 88 comprises the hollow sleeve 90 (see Fig. 4) having the aperture 92 formed on the peripheral side thereof. The follower 44 consists of stub shaft 94 which locks roller 96 to the hollow sleeve 90 via the recess 98. A washer 100 may be used to assure that the roller has sufficient spacing so that its rolling around shaft 94 is not impaired. In accordance with this invention, two (2) thrust pins 102 and 104 fit into annular groove 106 formed in the cam. The thrust pins 102 and 104 are grounded to the cam casing 108.

[0021] In operation, the motor drives pinion gear 66 which, in turn, meshes with the three (3) planetary gears 70 which, in turn, meshes with the fixed ring gear 72. This re-action of all of the above mentioned gears rotates the cam 69 via the platen 76 that is formed integral with the cam 69, and, as a consequence, rotates therewith. This rotary motion, in turn, is converted to reciprocal motion via the follower 44 that drives the drum rectilinearly which defines the reciprocal motion. Obviously, this motion is translated to the file by the connection described above.

[0022] Also, in accordance with this invention, the file is unique as will be described in detail herein below. As mentioned above the file assembly comprises an outer tube or tubular casing 112 that has integrally formed thereon at the distal end a flat and angular shaped shield and guide member 115. The solid tubular insert 114, resembling a rod, is tightly fitted into tube 112 and formed within the tubular insert 114 are the "infinity-shaped" slot 116 and a pair of lumens 46 and 47. (See fig. 2A) The generally flat file 50 fits into the infinity slot 116 and extends beyond the distal end of the solid rod 114 and is contiguous to the upper surface of the guide portion 115 and slides in rectilinearly thereon. In its preferred embodiment, the file assembly is bent 30 degrees adjacent to the proximal end and the same angle adjacent to the distal end. Obviously, the particular shape of the file assembly will be predicated on the particular use given the surgical file instrument.

[0023] As shown in Figs. 6-8, the cutting surface of the blade 54 of file 50 consists of a plurality of radial projecting ring-like elements 120 that serve as cutting edges 122. As mentioned earlier, the particular file head is not a concern of this invention. However, of importance is the shape of the shield 115 which is located at the distal end of tube 112. The shield 115 is formed at the distal end of the outer tube 112 that flairs into a generally flat portion 117 with the side edges 119 and 121 upturned to engage the side edges on the under surface of the blade 54 of file 50. Formed on shield 115 is the elongated dimple 124 extending longitudinally along the central portion of shield 115. The dimple includes the apex 126 and the straight slopes 128 and 130 extending from either sides thereof. This particular configuration centers the file and keeps its motion in a linear straight line which obviously, is important for the delicate types of operation to which the surgical file instrument is used. The lower portion of the shield 115 extends radially toward the outer edges of file 50 and are is bent slightly upwardly to be in contiguous contact with the side edges of file 50 as described above and together with the dimple 124 the blade 54 rides in a true line during its reciprocating condition.

[0024] Although this invention has been shown and described with respect to detailed embodiments thereof, it will be appreciated and understood by those skilled in the art that various changes in form and detail thereof may be made without departing from the scope of the disclosed invention.

Claims

1. A surgical file instrument (10)
comprising a tubular casing supporting a
reciprocating surgical file (50), said reciprocating surgical file (50) having a blade (54) at the distal end and a tang (56) at its opposite end,
a solid tubular member (114) supported in said tubular casing (112) having an elongated lumen (116)
for receiving said reciprocating surgical file (50) wherein said blade (54) is located at the distal end thereof and projects there-beyond and said tang (56) is located at the proximal end thereof and projects there- beyond,
a rotary motor (16), and
a motion converter (18) comprising a split casing (12),
said motion converter (18) including means in said split casing (12) for converting rotary motion to reciprocal motion,
a shaft (48), and
a source of power for powering said motor (16) for causing said blade (54) to reciprocate,
characterised in said means of the motion convertor (18) including a planetary gear system (70) to be driven by said motor (16),
and wherein the instrument further comprises a drum (88), wherein the shaft is attached to one end of said drum (88) and is attached to said tang for imparting reciprocal motion to said blade (54), and
a cam (69) having a cam slot (80) and a cam follower (44) fitted in said cam slot (80), said cam (69) operatively connected to said planetary gear system (70) and said cam follower (44) operatively connected to said drum, wherein, when the planetary gear system (70) rotates the cam (69), the rotary motion is converted to reciprocal motion via the cam follower (44) that reciprocates said drum (88).

2. A surgical file instrument as claimed in claim 1 including an annular groove (106) formed in said cam (69),
at least one thrust pin (102) extending from said cam casing (12) extending into said annular groove (106) for absorbing thrust loads imposed on said cam (69).

3. A surgical file instrument as claimed in claim 1 or 2 including a platen (76) on one end of said cam (69),
a plurality of shafts (74) circumferentially spaced around said platen (76), one of said planetary gears (70) being attached to each of said shafts for imparting rotary motion to said platen (76).

4. A surgical file instrument as claimed in claim 1, 2 or 3 wherein said source of power is a battery (14).

5. A surgical file instrument as claimed in any preceding claim wherein said tubular casing (112) encapsulates said solid tubular member (114).

6. A surgical file instrument as claimed in claim 5 wherein said tubular casing (112) includes a flattened portion formed on the distal end and being adjacent to said blade (54) and defining a combined guide and shield member (115).

7. A surgical file instrument as claimed in any preceding claim wherein said elongated lumen (116) is shaped like an infinity symbol.

8. A surgical file instrument as claimed in any preceding claim wherein the motor (16) is configured to drive a pinion gear (66), which is configured to mesh with the planetary gear system (70) which, in turn, is configured to mesh with a fixed ring gear (72), such that the cam (69) can rotate in reaction to the motion of the pinion gear (66), the planetary gear system (70) and the fixed ring gear (72).

9. A surgical file instrument as claimed in any preceding claim wherein the planetary gear system (70) includes three planetary gears (70).

10. A surgical file instrument as claimed in claim 3 or any preceding claim dependent on claim 3 wherein the cam (69) is rotated via the platen (76) that is formed integrally with the cam (69) and configured to rotate therewith.

Ansprüche

1. Ein chirurgisches Feilinstrument (10), umfassend

ein rohrförmiges Gehäuse, das eine hin- und hergehende chirurgische Feile (50) stützt, wobei die besagte hin- und hergehende chirurgische Feile (50) eine Klinge (54) an dem distalen Ende und eine Angel (56) an ihrem gegenüberliegenden Ende hat,

ein festes rohrförmiges Element (114) gestützt in dem besagten rohrförmigen Gehäuse (112) mit einem länglichen Lumen (116) zum Empfangen der besagten hin- und hergehenden chirurgischen Feile (50), wobei die besagte Klinge (54) sich an dem distalen Ende davon befindet und darüber hinaus ragt und wobei sich die besagte Angel (56) an dem proximalen Ende davon befindet und darüber hinaus ragt,

ein Drehmotor (16), und

ein Bewegungsumwandler (18), der ein geteiltes Gehäuse (12) umfasst, wobei der besagte Bewegungsumwandler (18) in dem besagten geteilten Gehäuse (12) Mittel zum Umwandeln einer Drehbewegung in eine hin- und hergehende Bewegung umfasst,

ein Schaft (48), und

eine Energiequelle zum Antreiben des besagten Motors (16) zum Bewirken, dass die besagte Klinge (54) hin- und hergeht,

dadurch gekennzeichnet, dass das besagte Mittel des Bewegungsumwandlers (18) ein Planetengetriebesystem (70) umfasst, um durch den besagten Motor (16) angetrieben zu werden,

und wobei das Instrument weiter eine Trommel (88) umfasst, wobei der Schaft an einem Ende der besagten Trommel (88) angebracht ist und an der besagten Angel angebracht ist, um der besagten Klinge (54) eine hin- und hergehende Bewegung zu vermitteln, und

eine Nocke (69) mit einem Nockenschlitz (80) und einem in dem besagten Nockenschlitz (80) eingebauten Nockenfolger (44), wobei die besagte Nocke (69) mit dem besagten Planetengetriebesystem (70) operativ verbunden ist und der besagte Nockenfolger (44) mit der besagten Trommel operativ verbunden ist, wobei, wenn das Planetengetriebesystem (70) die Nocke (69) dreht, die Drehbewegung über den Nockenfolger (44), der die besagte Trommel (88) hin- und her bewegt, in eine hin- und hergehende Bewegung umgewandelt wird.

2. Ein chirurgisches Feilinstrument wie in Anspruch 1 beansprucht, das eine in der besagten Nocke (69) ausgebildete ringförmige Nut (106) umfasst,

wobei sich mindestens ein Schubstift (102), der sich von dem besagten Nockengehäuse (12) erstreckt, in die besagte ringförmige Nut (106) hinein erstreckt, um der besagten Nocke (69) aufgebürdete Schubbelastungen zu absorbieren.

3. Ein chirurgisches Feilinstrument wie in Anspruch 1 oder 2 beansprucht, das eine Platte (76) an einem Ende der besagten Nocke (69) umfasst,

wobei eine Vielzahl von Schäften (74) um die besagte Platte (76) in Umfangsrichtung herum beabstandet ist,

wobei eines der besagten Planetenräder (70) an jedem der besagten Schäfte angebracht ist, um der besagten Platte (76) eine Drehbewegung zu vermitteln.

4. Ein chirurgisches Feilinstrument wie in Anspruch 1, 2 oder 3 beansprucht, wobei die besagte Energiequelle eine Batterie (14) ist.

5. Ein chirurgisches Feilinstrument wie in einem vorangegangenen Anspruch beansprucht, wobei das besagte rohrförmige Gehäuse (112) das besagte feste rohrförmige Element (114) einkapselt.

6. Ein chirurgisches Feilinstrument wie in Anspruch 5 beansprucht, wobei das besagte rohrförmige Gehäuse (112) einen abgeflachten Abschnitt umfasst, der an dem distalen Ende ausgebildet ist und benachbart zu der besagten Klinge (54) ist und eine kombiniertes Führungs- und Schildelement (115) definiert.

7. Ein chirurgisches Feilinstrument wie in einem vorangegangenen Anspruch beansprucht, wobei das besagte längliche Lumen (116) wie ein Unendlichkeitssymbol geformt ist.

8. Ein chirurgisches Feilinstrument wie in einem vorangegangenen Anspruch beansprucht, wobei der Motor (16) dazu konfiguriert ist, um ein Zahnradgetriebe (66) anzutreiben, das dazu konfiguriert ist, um mit dem Planetengetriebesystem (70) ineinanderzugreifen, das wiederum dazu konfiguriert ist, um mit einem festen Zahnkranz (72) ineinanderzugreifen, so dass sich die Nocke (69) als Reaktion auf die Bewegung des Zahnradgetriebes (66), des Planetengetriebesystems (70) und des festen Zahnkranzes (72) drehen kann.

9. Ein chirurgisches Feilinstrument wie in einem vorangegangenen Anspruch beansprucht, wobei das Planetengetriebesystem (70) drei Planetenräder (70) umfasst.

10. Ein chirurgisches Feilinstrument wie in Anspruch 3 oder einem vorangegangenen Anspruch, der von Anspruch 3 abhängig ist, beansprucht, wobei die Nocke (69) über die Platte (76) gedreht wird, die integral mit der Nocke (69) ausgebildet ist und dazu konfiguriert ist, sich damit zu drehen.

Revendications

1. Instrument de lime chirurgicale (10) comprenant un logement tubulaire supportant une lame chirurgicale à mouvement de réciprocité (50), ladite lime chirurgicale à mouvement de réciprocité (50) ayant une lame (54) à l'extrémité distale et un tenon (56) à son extrémité opposée,
un élément tubulaire solide (114) supporté dans ledit logement tubulaire (112) ayant une lumière allongée (116)
pour recevoir ladite lime chirurgicale à mouvement de réciprocité (50) dans lequel ladite lame (54) est située à l'extrémité distale de celle-ci et se projette au-delà de celle-ci et ledit tenon (56) est situé à l'extrémité proximale de celle-ci et se projette au-delà de celle-ci,
un moteur rotatif (16), et
un convertisseur de mouvement (18) comprenant un logement divisé (12),
ledit convertisseur de mouvement (18) comprenant des moyens dans ledit logement divisé (12) pour convertir le mouvement de rotation en mouvement de réciprocité,
une tige (48), et
une source d'énergie pour alimenter ledit moteur (16) pour amener la lame (54) à effectuer un mouvement de réciprocité,
caractérisé en ce que ledit moyen du convertisseur de mouvement (18) comprend un système d'engrenage planétaire (70) destiné à être entraîné par ledit moteur (16),
et dans lequel l'instrument comprend en outre un tambour (88), dans lequel la tige est fixée à une extrémité dudit tambour (88) et est fixée audit tenon pour conférer un mouvement de réciprocité à ladite lame (54), et
une came (69) ayant une fente de came (80) et un galet de came (44) ajusté dans ladite fente de came (80), ladite came (69) étant raccordée fonctionnellement audit système d'engrenage planétaire (70) et ledit galet de came (44) étant raccordé fonctionnellement audit tambour, dans lequel, lorsque le système d'engrenage planétaire (70) fait tourner la came (69), le mouvement de rotation est converti en mouvement de réciprocité via le galet de came (44) qui fait effectuer un mouvement de réciprocité audit tambour (88).

2. Instrument de lime chirurgicale selon la revendication 1 comprenant une rainure annulaire (106) formée dans ladite came (69),
au moins une tige poussoir (102) s'étendant dudit logement de came (12) s'étendant dans ladite rainure annulaire (106) pour absorber des charges de poussée imposées sur ladite came (69).

3. Instrument de lime chirurgicale selon la revendication 1 ou 2 comprenant un plateau (76) sur une extrémité de ladite came (69),
une pluralité de tiges (74) espacées circonférentiellement autour dudit plateau (76), l'un desdits engrenages planétaires (70) étant fixé à chacune desdites tiges pour conférer un mouvement rotatif audit plateau (76).

4. Instrument de lime chirurgicale selon la revendication 1, 2 ou 3 dans lequel ladite source d'énergie est une batterie (14).

5. Instrument de lime chirurgicale selon l'une quelconque des revendications précédentes dans lequel ledit logement tubulaire (112) encapsule ledit élément tubulaire solide (114).

6. Instrument de lime chirurgicale selon la revendication 5 dans lequel ledit logement tubulaire (112) comprend une partie aplatie formée sur l'extrémité distale et étant adjacente à ladite lame (54) et définissant un guide et un élément de blindage (115) combinés.

7. Instrument de lime chirurgicale selon l'une quelconque des revendications précédentes dans lequel ladite lumière allongée (116) est formée comme un symbole d'infinité.

8. Instrument de lime chirurgicale selon l'une quelconque des revendications précédentes dans lequel le moteur (16) est configuré pour entraîner un engrenage à pignon (66), qui est configuré pour s'engrener avec le système d'engrenage planétaire (70) qui est, lui-même, configuré pour s'engrener avec un engrenage annulaire fixe (72), de sorte que la came (69) puisse tourner en réaction à un mouvement de l'engrenage à pignon (66), du système d'engrenage planétaire (70) et de l'engrenage annulaire fixe (72).

9. Instrument de lime chirurgicale selon l'une quelconque des revendications précédentes dans lequel le système d'engrenage planétaire (70) comprend trois engrenages planétaires (70).

10. Instrument de lime chirurgicale selon la revendication 3 ou l'une quelconque des revendications précédentes dépendantes de la revendication 3 dans lequel la came (69) tourne via le plateau (76) qui est formé d'un seul tenant avec la came (69) et configuré pour tourner avec celle-ci.

Drawing